Cradle system for shaping fuselage sections

ABSTRACT

A method and apparatus for shaping fuselage sections. A first fuselage section is held in a holding structure in a cradle in a cradle system. Force are applied to the first fuselage section with an actuator system to a portion of the first fuselage section such that a first current shape of the first fuselage section changes towards a first desired shape for the first fuselage section to join the first the fuselage section to a second fuselage section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to the following patent applications:entitled “Fuselage Manufacturing System”, Ser. No. 14/488,984, andentitled “Metrology System for Generating Measurements of FuselageSections”, Ser. No. 14/489,057, issued as U.S. Pat. No. 9,453,720; filedeven date hereof and assigned to the same assignee. Each of theaforementioned applications is incorporated herein by reference in itsentirety.

BACKGROUND INFORMATION 1. Field

The present disclosure relates generally to manufacturing objects and,in particular, to manufacturing aircraft. Still more particularly, thepresent disclosure relates to a method and apparatus for joiningcomposite fuselage sections to each other.

2. Background

Aircraft are being designed and manufactured with greater and greaterpercentages of composite materials. Composite materials are used inaircraft to decrease the weight of the aircraft. This decreased weightimproves performance features such as payload capacities and fuelefficiencies. Further, composite materials provide longer service lifefor various components in an aircraft.

Composite materials are tough, light-weight materials created bycombining two or more functional components. For example, a compositematerial may include reinforcing fibers bound in polymer resin matrix.The fibers may be unidirectional or may take the form of a woven clothor fabric. The fibers and resins are arranged and cured to form acomposite material.

Further, using composite materials to create aerospace compositestructures potentially allows for portions of an aircraft to bemanufactured in larger pieces or sections. For example, a fuselage in anaircraft may be created in cylindrical sections and then assembled toform the fuselage of the aircraft. Other examples include, withoutlimitation, wing sections joined to form a wing, or stabilizer sectionsjoined to form a stabilizer.

With fuselage sections that are cylindrical, the dimensions of thefuselage sections are important to provide a desired fit when joiningthese sections to each other to form the fuselage of the aircraft. Forexample, the ends of two fuselage sections are joined to form part ofthe fuselage of the aircraft. The shape of these ends should match asclosely as possible.

A difference in the shapes of the ends may result in an undesired fit.Differences in the shapes of the ends may result from different causes.For example, variations from design specification in manufacturing thefuselage sections may cause an undesired shape at the ends. The fuselagesections are large enough that gravity may cause deformation thatchanges the shape of the fuselage sections such that the ends do nothave a desired shape to be joined to each other.

This undesired fit may cause the fuselage of the aircraft to perform ina less than desired manner. For example, if the fuselage sections arejoined with the undesired shapes, the amount of fuel used may increasefrom undesired airflow that may occur during flight. Also, undesiredairflow may cause increased noise that may reduce pleasantness of theflight experience for passengers.

Currently, operators on the manufacturing floor move ends of the twofuselage sections next to each other for joining. The operators measurethe differences in the shape of the ends using tools such as feelergauges. Changes to the shape of one or both fuselage ends are made usingjacks or other tools placed and operated by the operators to push on thefuselage sections to change the shape of one or both of the fuselagesections.

The currently used process for joining the fuselage sections is timeconsuming and labor intensive. Additionally, the shapes of the twofuselage sections may be close but may still not have a desired level offit between them.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. For example, it would be advantageous to havea method and apparatus for joining fuselage sections for an aircraftwith a desired level of fit.

SUMMARY

In one illustrative embodiment, an apparatus comprises a holdingstructure and an actuator system. The holding structure holds a fuselagesection. The actuator system applies forces to the fuselage sectionwhile the fuselage section is held in the holding structure in which theforces change a current shape of the fuselage section towards a desiredshape when commands are received from a controller.

In another illustrative embodiment, a method for shaping fuselagesections is presented. A first fuselage section is held in a holdingstructure in a cradle in a cradle system. Forces are applied to thefirst fuselage section with an actuator system to a portion of the firstfuselage section such that a first current shape of the first fuselagesection changes towards a first desired shape for the first fuselagesection to join the first the fuselage section to a second fuselagesection.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of an aircraftmanufacturing environment in accordance with an illustrative embodiment;

FIG. 2 is an illustration of a block diagram of a cradle system inaccordance with an illustrative embodiment;

FIG. 3 is an illustration of a block diagram of a metrology system inaccordance with an illustrative embodiment;

FIG. 4 is an illustration of a block diagram of data flow foridentifying forces to be applied to a fuselage section in accordancewith an illustrative embodiment;

FIG. 5 is an illustration of a feedback loop in accordance with anillustrative embodiment;

FIG. 6 is an illustration of an aircraft manufacturing environment inaccordance with an illustrative embodiment;

FIG. 7 is an illustration of fuselage sections in a fuselagemanufacturing system in accordance with an illustrative embodiment;

FIG. 8 is an illustration of a cradle in accordance with an illustrativeembodiment;

FIG. 9 is an illustration of a view of a first cradle in accordance withan illustrative embodiment;

FIG. 10 is an illustration of an actuator in accordance with anillustrative embodiment;

FIG. 11 is another illustration of an actuator in accordance with anillustrative embodiment;

FIG. 12 is an illustration of a metrology system setup in accordancewith an illustrative embodiment;

FIG. 13 is an illustration of a flowchart of a process for processingfuselage sections in accordance with an illustrative embodiment;

FIG. 14 is an illustration of a flowchart of a process for applyingforces to a fuselage section in accordance with an illustrativeembodiment;

FIG. 15 is an illustration of a flowchart of a process for generatingmeasurements of fuselage sections using a metrology system in accordancewith an illustrative embodiment;

FIG. 16 is an illustration of a flowchart of a process for identifyingforces for changing the shape of a fuselage section in accordance withan illustrative embodiment;

FIG. 17 is an illustration of a flowchart of a process for joiningfuselage sections in accordance with an illustrative embodiment;

FIG. 18 is an illustration of an aircraft manufacturing and servicemethod in the form of a block diagram in accordance with an illustrativeembodiment; and

FIG. 19 is an illustration of an aircraft in the form of a block diagramin which an illustrative embodiment may be implemented.

DETAILED DESCRIPTION

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of a block diagram of an aircraft manufacturingenvironment is depicted in accordance with an illustrative embodiment.In this example, aircraft manufacturing environment 100 includesfuselage manufacturing system 102, which is used to join fuselagesections 103 to each other as part of manufacturing an aircraft.

In this illustrate example, fuselage manufacturing system 102 joinsfirst fuselage section 104 to second fuselage section 106 in fuselagesections 103 using a number of components. As depicted, components infuselage manufacturing system 102 include cradle system 108, metrologysystem 110, and controller 112.

Cradle system 108 is a physical apparatus. As depicted, cradle system108 holds first fuselage section 104 and applies forces 114 to firstfuselage section 104 to change first current shape 116 of first fuselagesection 104.

The application of forces 114 by cradle system 108 to first fuselagesection 104 causes first deformation 118 to first fuselage section 104.Forces 114 may be applied in a manner that causes first deformation 118such that first current shape 116 of first fuselage section 104 changestowards first desired shape 120 for first fuselage section 104.

In this illustrative example, first current shape 116 and first desiredshape 120 are contours 121 for first fuselage section 104. Inparticular, the contours are those around circumference 122 of firstfuselage section 104.

Additionally, a portion of forces 114 generated by cradle system 108also may be applied to second fuselage section 106. Cradle system 108applies forces 114 in a manner that causes second deformation 123. As aresult, second current shape 124 of second fuselage section 106 hassecond deformation 123 and second current shape 124 changes towardssecond desired shape 126 for second fuselage section 106.

In other words, cradle system 108 may apply forces 114 to change atleast one of first current shape 116 of first fuselage section 104towards first desired shape 120 or second current shape 124 of secondfuselage section 106 towards second desired shape 126. As used herein,the phrase “at least one of,” when used with a list of items, meansdifferent combinations of one or more of the listed items may be usedand only one of each item in the list may be needed. In other words, atleast one of means any combination of items and number of items may beused from the list but not all of the items in the list are required.The item may be a particular object, thing, or a category.

For example, without limitation, “at least one of item A, item B, oritem C” may include item A, item A and item B, or item B. This examplealso may include item A, item B, and item C or item B and item C. Ofcourse, any combinations of these items may be present. In someillustrative examples, “at least one of” may be, for example, withoutlimitation, two of item A; one of item B; and ten of item C; four ofitem B and seven of item C; or other suitable combinations.

In this illustrative example, metrology system 110 is a hardware sensorsystem. Metrology system 110 makes measurements 128 of fuselage sections103. As depicted, measurements 128 are made without contact or touchingfuselage sections 103.

For example, metrology system 110 makes measurements 128 of firstcurrent shape 116 of first fuselage section 104. Metrology system 110also may make measurements 128 of second current shape 124 of secondfuselage section 106.

In the illustrative example, controller 112 controls operation of cradlesystem 108 and metrology system 110. Controller 112 may be implementedin software, hardware, firmware or a combination thereof. When softwareis used, the operations performed by controller 112 may be implementedin program code configured to run on hardware, such as a processor unit.When firmware is used, the operations performed by controller 112 may beimplemented in program code and data and stored in persistent memory torun on a processor unit. When hardware is employed, the hardware mayinclude circuits that operate to perform the operations in controller112.

In the illustrative examples, the hardware may take the form of acircuit system, an integrated circuit, an application specificintegrated circuit (ASIC), a programmable logic device, or some othersuitable type of hardware configured to perform a number of operations.With a programmable logic device, the device may be configured toperform the number of operations. The device may be reconfigured at alater time or may be permanently configured to perform the number ofoperations. Examples of programmable logic devices include, for example,a programmable logic array, a programmable array logic, a fieldprogrammable logic array, a field programmable gate array, and othersuitable hardware devices. Additionally, the processes may beimplemented in organic components integrated with inorganic componentsand may be comprised entirely of organic components excluding a humanbeing. For example, the processes may be implemented as circuits inorganic semiconductors.

In this illustrative example, controller 112 is located in computersystem 132. Computer system 132 includes one or more data processingsystems. When more than one data processing system is present, thosedata processing systems may be in communication with each other using acommunications medium such as a network. The data processing systems maybe selected from at least one of a computer, a server computer, atablet, a mobile phone, or some other suitable data processing system.

As depicted in this illustrative example, controller 112 receivesmeasurements 128 from metrology system 110. Controller 112 identifiesforces 114 needed to change first current shape 116 of first fuselagesection 104 to first desired shape 120 for connecting first fuselagesection 104 to second fuselage section 106. Controller 112 then sendscommands 134 to cradle system 108 to apply forces 114 to change firstcurrent shape 116 of first fuselage section 104 towards first desiredshape 120.

When forces 114 are applied to first fuselage section 104, the change infirst current shape 116 may not result in first desired shape 120.Instead, first current shape 116 may be closer to first desired shape120 but not quite reaching first desired shape 120.

In this case, measurements 128 may be made again by metrology system110. In this illustrative example, measurements 128 are new measurements140 made by metrology system 110 after cradle system 108 applies forces114 to first fuselage section 104 to change first current shape 116 offirst fuselage section 104 towards first desired shape 120.

Controller 112 uses new measurements 140 as a feedback to identifyforces 114 needed to change first current shape 116 of first fuselagesection 104 further towards first desired shape 120 if first desiredshape 120 has not been reached. Controller 112 sends commands 134 in theform of new commands 142 to cradle system 108 to apply forces 114 tochange first current shape 116 of first fuselage section 104 towardsfirst desired shape 126.

Further, measurements 128 from metrology system 110 may includemeasurements for second fuselage section 106. In this particularexample, controller 112 identifies forces 114 needed to change secondcurrent shape 124 of second fuselage section 106 towards second desiredshape 126 for connecting first fuselage section 104 to second fuselagesection 106. Controller 112 then sends commands 134 to cradle system 108causing cradle system 108 to apply forces 114 to change second currentshape 124 of second fuselage section 106 towards second desired shape126.

In the illustrative example, first desired shape 120 is based on atleast one of second current shape 124 of second fuselage section 106, amodel of first fuselage section 104, parameters specified by a designfor first fuselage section 104, or some other standard or specification.For example, first desired shape 120 for first fuselage section 104 maybe second current shape 124 for second fuselage section 106. In anotherexample, second desired shape 126 for second fuselage section 106 may befirst current shape 116 for first fuselage section 104.

In this manner, fuselage sections 103 may be joined to each other in adesired manner more efficiently than with currently used techniques.With fuselage manufacturing system 102, the amount of time and laborneeded to join fuselage sections 103 to each other may be reduced.Further, a desired level of fit between first fuselage section 104 andsecond fuselage section 106 may be achieved with less effort or time. Inthis manner, the time and expense needed to manufacture a fuselage maybe reduced as well as provide for a desired level of fit betweenfuselage sections 103.

With reference next to FIG. 2, an illustration of a block diagram of acradle system is depicted in accordance with an illustrative embodiment.As depicted, an example of an implementation for cradle system 108 inFIG. 1 is depicted. In this illustrative example, cradle system 108includes a group of cradles 200. As used herein, a “group of,” when usedwith reference items means one or more items. For example, a group ofcradles 200 is one or more of cradles 200.

In this example, cradle 202 in the group of cradles 200 includes anumber of components. As depicted, holding structure 201 and actuatorsystem 203 are components that form cradle 202. As depicted, cradle 202is mobile. In other words, cradle 202 is configured to move withinaircraft manufacturing environment 100 in FIG. 1. For example, cradle202 may be movable by a human operator, a vehicle, or may include amovement system.

Holding structure 201 holds fuselage section 204. Fuselage section 204is an example of a fuselage section in fuselage sections 103 in FIG. 1.In this illustrative example, actuator system 203 applies forces 210 tofuselage section 204 while fuselage section 204 is held in holdingstructure 201. Forces 210 change current shape 212 of fuselage section204 towards desired shape 214 when commands 134 are received fromcontroller 112 in FIG. 1.

In the depicted example, actuator system 203 may apply forces 210 toportion 215 of fuselage section 204 to change current shape 212 offuselage section 204. Portion 215 may be some or all of fuselage section204 depending on the particular implementation. For example, portion 215may be about one half of a circumference of the fuselage section. Asanother example, actuator system 203 applies forces 210 to portion 215of fuselage section 204 located at end 216 of fuselage section 204.

As depicted, actuator system 203 is formed from a number of differentcomponents. As depicted, components in actuator system 203 includeactuators 217 and frame 218.

In this illustrative example, actuators 217 may be implemented using oneor more different types of actuators. For example, actuators 217 may beselected from at least one of a linear actuator, a hydraulic actuator, apneumatic actuator, an electro mechanical actuator, or some othersuitable type of actuator.

As depicted, frame 218 is a structure that holds actuators 217. Inparticular, actuators 217 are physically associated with frame 218. Whenone component is “associated” with another component, the association isa physical association in the depicted examples. For example, a firstcomponent may be considered to be physically associated with a secondcomponent by at least one of being secured to the second component,bonded to the second component, mounted to the second component, weldedto the second component, fastened to the second component, or connectedto the second component in some other suitable manner. The firstcomponent also may be connected to the second component using a thirdcomponent. The first component may also be considered to be physicallyassociated with the second component by being formed as part of thesecond component, extension of the second component, or both.

In this illustrative example, frame 218 holds actuators 217 in positons220 around fuselage section 204 when fuselage section 204 is held inholding structure 201 in cradle 202. For example, frame 218 may holdactuators 217 such that actuators 217 are positioned at end 216 offuselage section 204 held in holding structure 201.

With reference next to FIG. 3, an illustration of a block diagram of ametrology system is depicted in accordance with an illustrativeembodiment. As depicted, an example of an implementation for metrologysystem 110 in FIG. 1 is depicted.

In this illustrative example, metrology system 110 makes measurements300 of fuselage section 302. Fuselage section 302 is an example of afuselage section in fuselage sections 103 in FIG. 1. Measurements 300are examples of measurements 128 in FIG. 1.

As depicted, metrology system 110 is touchless metrology system 304. Inother words, metrology system 110 does not require physical contact withfuselage section 302 to generate measurements 300.

Instead, metrology system 110 may use signals 306 to generatemeasurements 300. As depicted, signals 306 may include at least one oflight, infrared signals, radio frequency signals, or other suitabletypes of signals. In this illustrative example, touchless metrologysystem 304 takes the form of optical metrology system 308.

Metrology system 110 includes a number of different components. In thisparticular example, metrology system 110 includes scanning system 310and targets 312.

As depicted, scanning system 310 transmits signals 306 to generatemeasurements 300. In this illustrative example, scanning system 310includes at least one of a lidar system, a laser scanning system, orsome other suitable type of device. In other words, one or more of thesedevices or other suitable devices may be used in any combination inscanning system 310.

Scanning system 310 may be selected such that scanning system 310 maytransmit signals 306, detect reflected signals 318, or both in about 360degrees. The detection may be performed without moving, realigning, orotherwise changing the position of scanning system 310 whiletransmitting signals 306 or detecting reflected signals 318.

In other words, metrology system 110 with scanning system 310 andtargets 312 is self-referencing. In being self-referencing, absolutepositioning is not needed to obtain a desired resolution in generatingmeasurements 300. The desired resolution may be obtained without anydependency on an absolute positioning of system scanning system 310,targets 312, or both.

Targets 312 are structures that reflect signals 306. Reflected signals318 are detected by scanning system 310 and are used to generatemeasurements 300. Targets 312 may be selected from at least one ofreflective tape, a tooling ball, a feature on fuselage section 302, orsome other suitable target. In other words, targets 312 may be attachedto fuselage section 302, already present as part of fuselage section 302as manufactured, or some combination thereof.

Using features in fuselage section 302 reduces the time and effortneeded to shape and join fuselage section 302 to other structures. Forexample, attaching and removing targets is unnecessary. Also, inspectingfuselage section 302 for debris, inconsistencies in fuselage section 302from targets 312 is avoided. The feature may be any structure or portionof fuselage section 302 that reflects signals 306.

In this illustrative example, metrology system 110 may be used togenerate measurements of two fuselage sections. For example, fuselagesection 302 is first fuselage section 314 and scanning system 310 may bepositioned relative to first fuselage section 314 and second fuselagesection 316. These two fuselage sections may be held in cradle system108 in FIG. 1. For example, scanning system 310 may be positionedbetween first fuselage section 314 and second fuselage section 316.

Targets 312 are located on both first fuselage section 314 and secondfuselage section 316 in this illustrative example. In particular,targets 312 may be located on first interior surface 320 of firstfuselage section 314 and second interior surface 322 of second fuselagesection 316.

Scanning system 310 transmits signals 306 at targets 312 on firstfuselage section 314 and second fuselage section 316. Reflected signals318 from targets 312 are detected by scanning system 310. As depicted,scanning system 310 generates measurements 300 from reflected signals318 from both first fuselage section 314 and second fuselage section316. When both first fuselage section 314 and second fuselage section316 are present instead of just first fuselage section 314, thepositioning of scanning system 310 is selected such that scanning system310 is able to direct signals 306 to targets 312 on both first fuselagesection 314 and second fuselage section 316 at substantially the sametime.

In the illustrative example, signals 306 may be a group of beams oflight 324. In on illustrative example, the group of beams of light 324may be group of laser beams. If a single laser beam is used, scanningsystem 310 may use a mirror or other reflector to direct the laser beamto targets 312 on first fuselage section 314 and second fuselage section316 at substantially the same time.

In the illustrative example, metrology system 110 may operate on itsown. In other words, measurements 300 may be made without needed inputor changes from a human operator or some other device. Scanning system310 may receive a program, control file, or other information andoperate to perform measurements 300. Measurements 300 may be performedeach time metrology system 110 detects an event.

For example, measurements 300 may be performed each time metrologysystem 110 detects a change in the shape of at least one of firstfuselage section 314 or second fuselage section 316. Scanning system 310may transmit signal continuously or periodically to detect when theshape of at least one of first fuselage section 314 or second fuselagesection 316 changes.

With reference to FIG. 4, an illustration of a block diagram of dataflow for identifying forces to be applied to a fuselage section isdepicted in accordance with an illustrative embodiment. In this depictedexample, controller 112 identifies forces 114 to be applied to afuselage section, such as first fuselage section 104 shown in FIG. 1.

As depicted, controller 112 receives measurements 400 for a fuselagesection. Measurements 400 is an example of measurements 128 in FIG. 1.Controller 112 uses measurements 400 to identify current shape 402 for afuselage section. Controller 112 then identifies desired shape 404.

In these illustrative examples, desired shape 404 may be identified frommodel 406. Model 406 may be a model of the fuselage section with thedesired dimensions. In this illustrative example, model 406 is acomputer-aided design model. In another illustrative example, desiredshape 404 may be identified from current shape 402 for a second fuselagesection to which the fuselage section being processed is to be joined.

The process then identifies forces 410 to be applied to the fuselagesection. These forces may be identified using a number of differenttechniques. For example, finite element model 412 for the fuselagesection may be used to identify how different forces affect currentshape 402 for the fuselage section being processed. Based on theidentification of forces 410, controller 112 generates commands 414 thatare sent to a cradle holding the fuselage section to apply forces 410 asidentified by controller 112.

With reference now to FIG. 5, an illustration of a feedback loop isdepicted in accordance with an illustrative embodiment. In this depictedexample, feedback loop 500 is formed by cradle system 108, metrologysystem 110 and controller 112.

As depicted, metrology system 110 generates measurements 128 of fuselagesection 502 held in cradle system 108. In this illustrative example,fuselage section 502 is a fuselage section in fuselage sections 103 inFIG. 1.

Measurements 128 are sent by metrology system 110 to controller 112. Inturn, controller 112 uses measurements 128 to identify forces 114.Forces 114 are ones that should be applied to fuselage section 502 tochange current shape 504 of fuselage section 502 towards desired shape506 for fuselage section 502.

In the illustrative example, controller 112 generates commands 134 andsends commands 134 to cradle system 108. In turn, cradle system 108applies forces 114 to fuselage section 502. Changing current shape 504of fuselage section 502 towards desired shape 506 may mean that currentshape 504 may reach desired shape 506 or that current shape 504 iscloser to but does not reach desired shape 506 in the illustrativeexamples.

Metrology system 110 again generates measurements 128 after forces 114have been applied. Measurements 128 are sent to controller 112 to formfeedback loop 500. Feedback loop 500 is a closed loop that allows forincremental changes in current shape 504 in reaching desired shape 506.

In some cases, current shape 504 may reach desired shape 506 after thefirst application of forces 114 to fuselage section 502. In these cases,additional applications of forces 114 may be performed using feedbackloop 500 until desired shape 506 has been reached.

In this illustrative example, measurements 128 is a measurement ofcurrent shape 504. Controller 112 compares measurements 128 for currentshape 504 to parameters for desired shape 506 in determining whetherforces 114 should be applied to fuselage section 502. In otherillustrative examples, measurements 128 may be, for example, adifference between current shape 504 and desired shape 506 for fuselagesection 502.

The illustration of aircraft manufacturing environment 100 and thedifferent components in FIG. 1 is not meant to imply physical orarchitectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beunnecessary. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

For example, at least one of metrology system 110 or controller 112identifies a difference between first current shape 116 of firstfuselage section 104 and first desired shape 120 for first fuselagesection 104. In yet another illustrative example, other numbers offuselage sections may be processed in cradle system 108 in addition toor in place of first fuselage section 104 and second fuselage section106. For example, one, three, six, or some other number of fuselagesections 103 may be held and shaped in cradle system 108 with forces 114applied to change the current shapes of one or more of fuselage sections103 held in cradle system 108.

With reference now to FIG. 6, an illustration of an aircraftmanufacturing environment is depicted in accordance with an illustrativeembodiment. Aircraft manufacturing environment 600 is an example of onephysical implementation of aircraft manufacturing environment 100 shownin block form in FIG. 1.

In this illustrative example, fuselage manufacturing system 602 inaircraft manufacturing environment 600 includes a number of differentcomponents. As depicted, the components in aircraft manufacturingenvironment 600 include first cradle 604, second cradle 606, lasertracker 608, targets 610, and computer 612. These components areexamples of physical components for components shown in block form infuselage manufacturing system 102 in FIG. 1-4.

First cradle 604 and second cradle 606 form a cradle system in thisillustrative example. First cradle 604 and second cradle 606 areexamples of physical implementations for cradles 200 in cradle system108 shown in block form in FIG. 2.

Laser tracker 608 and targets 610 are part of a metrology system. Lasertracker 608 is an example of a physical implementation for scanningsystem 310 in metrology system 110 as shown in FIG. 3.

In this illustrative example, targets 610 are located on floor 614 ofaircraft manufacturing environment 600. Targets 610 may be placed onfuselage sections or other structures (not shown) and used by lasertracker 608 generating measurements. As depicted, targets 610 areexamples of physical implementations for targets 312 shown in block formin FIG. 3.

Computer 612 is a controller for fuselage manufacturing system 602.Computer 612 is an example of a physical implementation for controller112 in FIG. 1. In particular, computer 612 may be used to implement acomputer in computer system 132 shown in block form in FIG. 1.

As depicted, computer 612 is in communication with first cradle 604,second cradle 606, and laser tracker 608. In this particular example,the communication between these components occurs through acommunications medium that includes the use of wireless signals 616.

Turning next to FIG. 7, an illustration of fuselage sections in afuselage manufacturing system is depicted in accordance with anillustrative embodiment. In this illustrative example, first fuselagesection 700 is shown as being held in first cradle 604. Second fuselagesection 702 is depicted as being held in second cradle 606. Firstfuselage section 700 is an example of a physical implementation forfirst fuselage section 104 shown in block form in FIG. 1. Secondfuselage section 702 is an example of a physical implementation forsecond fuselage section 106 shown in block form in FIG. 1. In thisillustrative example, first cradle 604 and second cradle 606 mayactively change the shapes of first fuselage section 700 and secondfuselage section 702, respectively.

As depicted, targets 610 may be placed onto at least one of interiorsurface 704 of first fuselage section 700 or interior surface 706 ofsecond fuselage section 702. Targets 610 are seen in phantom on interiorsurface 704 of first fuselage section 700 in this view.

Targets 610 are used by laser tracker 608 to generate measurements forthe current shape of at least one of first fuselage section 700 orsecond fuselage section 702. These measurements may be, for example, atleast one of the current shape of first fuselage section 700, thecurrent shape of second fuselage section 702, a difference between thecurrent shape and a desired shape of first fuselage section 700, or adifference between the current shape and a desired shape of secondfuselage section 702, or some other standard or parameters that definethe desired shape for first fuselage section 700.

As depicted, these measurements are used by computer 612 to identifyforces needed to change the current shapes of first fuselage section700, second fuselage section 702, or both towards a desired shape forthose fuselage sections. Computer 612 sends commands to at least one offirst cradle 604 or second cradle 606 to apply forces to at least one offirst fuselage section 700 or second fuselage section 702.

With reference now to FIG. 8, an illustration of a cradle is depicted inaccordance with an illustrative embodiment. An end view of first cradle604 is shown in the direction of arrows 8-8 in FIG. 6.

In this view, first cradle 604 has a number of components. As depicted,these components include holding structure 800, frame 802, and actuators804.

Holding structure 800 has a design for holding a fuselage section whileforces are applied to the fuselage section. Holding structure 800 holdsthe fuselage section while measurements of the current shape of thefuselage section are made. Holding structure 800 also may be used toposition the fuselage section to be joined with another fuselagesection. In this illustrative example, the positioning may be performedby moving first cradle 604.

Frame 802 and actuators 804 form an actuator system. As show in thisexample, actuators 804 includes actuator 806, actuator 808, actuator810, actuator 812 actuator 814, actuator 816, actuator 818, actuator820, actuator 822, and actuator 824.

With reference next to FIG. 9, an illustration of a view of a firstcradle is depicted in accordance with an illustrative embodiment. Inthis illustrative example, first cradle 604 holding first fuselagesection 700 is a shown in the direction of arrows 9-9 in FIG. 7. In thisexample, first fuselage section 700 is held on holding structure 800.While held on holding structure 800, actuators 804 may apply forces tofirst fuselage section 700 to change the current shape of first fuselagesection 700 towards a desired shape for first fuselage section 700.

In this illustrate example, actuators 804 apply forces to a portion offirst fuselage section 700. As depicted, actuators 804 apply forces to aportion of first fuselage section 700 that is about one half ofcircumference 900 of first fuselage section 700. In this particularexample, the forces are applied to lower half 904 of first fuselagesection 700 resting on holding structure 800. A more detailedillustration of actuator 822 in section 906 is shown in FIG. 10 below.

Turning now to FIG. 10, an illustration of an actuator is depicted inaccordance with an illustrative embodiment. A more detailed illustrationof actuator 824 in section 906 is shown in this figure.

As depicted, actuator 824 is a linear actuator. Actuator 824 isassociated with frame 802 (not shown in this view) and positioned toapply a force on first fuselage section 700.

In this illustrative example, actuator 824 includes motor 1000 andlinear member 1002. Motor 1000 may take various forms depending on theparticular implementation. For example, motor 1000 may be electrical,hydraulic, pneumatic, or some other type of motor. Linear member 1002has foot 1004 at end 1006 that contacts surface 1008 of first fuselagesection 700.

Linear member 1002 in actuator 824 may move in the direction of arrow1010. Actuator 824 applies force in the direction of arrow 1012 in thisexample.

With reference now to FIG. 11, another illustration of an actuator isdepicted in accordance with an illustrative embodiment. In this example,actuator 1100 is an example of another actuator that may be used inactuators 804 in FIG. 8. As depicted, actuator 1100 is a linearactuator. Actuator 1100 has motor 1102 and linear member 1104.

Actuator 1100 has foot 1106 at end 1108 of linear member 1104. In thisexample, foot 1106 has a suction cup 1110. With suction cup 1110, foot1106 may apply force in the direction of arrow 1112. In other words,actuator 1100 may push or pull on a structure. Arrow 1112 shows that theforce may be applied in two directions in contrast to the singledirection of actuator 824 in FIG. 10.

With reference next to FIG. 12, an illustration of a metrology systemsetup is depicted in accordance with an illustrative embodiment. In thisparticular example, laser tracker 608 is positioned relative to firstfuselage section 700 to make measurements of the shape in interior 1200of first fuselage section 700.

As shown in this illustrative example, first fuselage section 700 isheld in first cradle 604 and second fuselage section 702 is held insecond cradle 606. First fuselage section 700 and second fuselagesection 702 are positioned such that axis 1210 extends substantiallycentrally through the interior of first fuselage section 700 and secondfuselage section 702.

In this example, a portion of targets 610 are attached to interiorsurface 704 of first fuselage section 700 as shown in phantom. Anotherportion of targets 610 are attached to interior surface 706 of secondfuselage section 702. Laser tracker 608 sends signals in the form oflaser beam 1215 towards the portion of targets 610 attached to interiorsurface 704 in interior 1200 of first fuselage section 700. Lasertracker 608 also sends laser beam 1208 towards the portion of targets610 attached to interior surface 706 in interior 1214 of second fuselagesection 702. Laser tracker 608 detects response signals to the laserbeams in the form of reflected light 1216 and reflected light 1218. Inthis manner, laser tracker 608 may make measurements of first fuselagesection 700 and second fuselage section 702 sequentially, or both firstfuselage section 700 and second fuselage section 702 at the same time.

The illustration of fuselage manufacturing system 602 in aircraftmanufacturing environment 600 in FIG. 6-12 is not meant to implylimitations to the manner in which other illustrative examples may beimplemented. For example, other illustrative examples may use othernumbers of actuators. In other illustrative examples, five, fifteen,twenty-four or some other number of actuators may be used. Also thepositioning of the actuators may vary in other illustrative examples.For example, the actuators may apply force over a portion that is 50percent, 80 percent, or another portion of the circumference of afuselage section.

As another example, axis 1210 may not be used to align first fuselagesection 700 and second fuselage section 702. Other positons for thesefuselage sections may be used and axis 1210 does not pass through thefuselage sections centrally. The fuselage sections may be in anyposition where laser tracker 608 is able to make measurements of thefuselage sections.

The different components shown in FIGS. 6-12 may be combined withcomponents in FIGS. 1-5, used with components in FIGS. 1-5, or acombination of the two. Additionally, some of the components in FIGS.6-12 may be illustrative examples of how components shown in block formin FIGS. 1-12 can be implemented as physical structures.

Turning next to FIG. 13, an illustration of a flowchart of a process forprocessing fuselage sections is depicted in accordance with anillustrative embodiment. The process in FIG. 13 may be implemented inaircraft manufacturing environment 100 to process fuselage sections 103.In particular, the different operations may be implemented usingfuselage manufacturing system 102 in FIG. 1.

The process begins by holding a first fuselage section in a cradlesystem (operation 1300). The process then measures the current shape ofthe first fuselage section in the cradle system (operation 1302).

The process identifies the forces needed to change the current shape ofthe first fuselage section to a desired shape for connecting the firstfuselage section to a second fuselage section (operation 1304). Inidentifying the forces, the process may identify a difference betweenthe current shape of the first fuselage section and the desired shapefor the first fuselage section using at least one of a metrology systemor a controller. This difference may then be used to identify forcesneeded to make a change in the shape of the first fuselage section. Theprocess then applies the forces identified using the cradle system tochange the current shape of the first fuselage section towards thedesired shape (operation 1306).

The process then measures the current shape of the first fuselagesection after the forces have been applied to the first fuselage section(operation 1308). A determination is made as to whether the currentshape has reached the desired shape for the first fuselage section(operation 1310).

If the current shape has reached the desired shape, the processterminates. Otherwise the process returns to operation 1304. Thisprocess may repeat operation 1304, operation 1306, operation 1308, andoperation 1310 as many times as needed to reach the desired shape forthe first fuselage section. The operations form a feedback loop foractively changing the current shape of the first fuselage section.

Further, different operations in FIG. 13 may be applied to a secondfuselage section. These operations may be applied to the first fuselagesection and a second fuselage section, sequentially, or about the sametime.

For example, the process may hold the second fuselage section in thecradle system and measure a second current shape of the second fuselagesection. The process may also identify the forces needed to change atleast one of the first current shape of the first fuselage sectiontowards the first desired shape or a second current shape of the secondfuselage section to a second desired shape for connecting the firstfuselage section to second fuselage section. Further, the process mayapply the forces to change at least one of the first current shape ofthe first fuselage section towards the first desired shape or the secondcurrent shape of the second fuselage section towards the second desiredshape.

With reference next to FIG. 14, an illustration of a flowchart of aprocess for applying forces to a fuselage section is depicted inaccordance with an illustrative embodiment. The process illustrated inFIG. 14 may be implemented in an aircraft manufacturing environment 100in FIG. 1. In particular, the processes may be implemented using cradle202 in cradle system 108 as shown in FIG. 2.

The process begins by holding a first fuselage section in a holdingstructure in a cradle system (operation 1400). Next, the processreceives commands identifying forces to be applied to the first fuselagesection (operation 1402).

The process then applies forces to the first fuselage section with anactuator system in the first cradle to a portion of the first fuselagesection such that a first current shape of the first fuselage sectionchanges towards a first desired shape (operation 1404). The firstdesired shape is a shape for the fuselage section that is desired forjoining the first fuselage section to a second fuselage section.

Turning to FIG. 15, an illustration of a flowchart of a process forgenerating measurements of fuselage sections using a metrology system isdepicted in accordance with an illustrative embodiment. The processillustrated in FIG. 15 may be implemented using metrology system 110 asdepicted in FIG. 3. In this example, scanning system 310 and targets 312in metrology system 110 are used to generate measurements of twofuselage sections.

The process begins by positioning a scanning system between a firstfuselage section held in a first cradle and a second fuselage sectionheld in a second cradle (operation 1500). The positioning of thescanning system may be performed by moving at least one of the scanningsystem, the first cradle, or the second cradle. The positioning is suchthat the scanning system is able to transmit signals, such as a group ofbeams of light to targets on at least one of the first fuselage sectionor the second fuselage section.

The process then places targets on a first interior surface of the firstfuselage section and a second interior surface of the second fuselagesection (operation 1502). The process then transmits a group of beams oflight from the scanning system to the targets on the first interiorsurface of the first fuselage section and the second interior surface ofthe second fuselage section (1504). The process detects a reflectedlight from the beam of light (operation 1506).

The process then generates measurements of the first fuselage sectionand the second fuselage section from using the reflected light generatedin response to the beam of light (operation 1508). In this illustrativeexample, the measurements may be the dimensions for the current shape ofthe first fuselage section and second fuselage section. In otherillustrative examples, the measurements may be a difference between acurrent shape and a desired shape for the fuselage sections. In yetother illustrative examples, both of these types of measurements may begenerated.

The process the sends the measurements to a controller (operation 1510).The controller uses these measurements to determine whether the forceshould be applied and what types of forces should be applied to thefuselage sections.

A determination is made as to whether to generate additionalmeasurements (operation 1512). For example, additional measurements maybe made each time a current shape of the first fuselage section ischanged. If additional measurements are to be generated, the processreturns to operation 1504. Otherwise the process terminates. Themeasurements enable shaping at least one of the first fuselage or thesecond fuselage for joining the first fuselage to the second fuselage.

With reference next to FIG. 16, an illustration of a flowchart of aprocess for identifying forces for changing the shape of a fuselagesection is depicted in accordance with an illustrative embodiment. Theprocess illustrated in FIG. 16 may be implemented in a controller, suchas controller 112 in FIG. 1.

The process begins by receiving measurements from a metrology system(operation 1600). The process then identifies a current shape of thefuselage section from the measurements (operation 1602). The processthen compares the current shape of the fuselage section to a desiredshape of the fuselage section (operation 1604). This comparison may bemade by using a model of the desired shape for the current fuselagesection or a model of the current shape of a second fuselage section towhich the fuselage section being processed is to be joined.

A determination is made as to whether the current shape has reached thedesired shape (operation 1606). If the current shape has reached thedesired shape, the process terminates.

Otherwise, the process identifies forces to be applied to the currentshape of the fuselage section to cause the current shape of the fuselagesection to move towards the desired shape for the fuselage section(operation 1608). In operation 1608, the forces may be identified usingvarious models. For example, a finite element model of the fuselagesection may be used to identify changes in the current shape of thefuselage section in response to the application of forces. Forces areselected to identify whether these changes cause the current shape ofthe fuselage section to move towards the desired shape. These forces maybe selected using various techniques. For example, at least one of anartificial intelligence program, a knowledgebase, an expert system, orsome other technique may be used to identify the forces.

Once the forces are identified, the process generates commands toactuators to apply the forces (operation 1610). The process then sendsthe identified commands to the actuators (operation 1612), with theprocess terminating thereafter. The process in FIG. 16 may be repeatedeach time measurements are received from a metrology system.

Turning now to FIG. 17, an illustration of a flowchart of a process forjoining fuselage sections is depicted in accordance with an illustrativeembodiment. The process illustrated in FIG. 17 may be implemented inaircraft manufacturing environment 100 in FIG. 1 to join fuselagesections to each other. This process may be used when the two fuselagesections have a desired shape for joining the two fuselage sections toeach other.

The process begins by positioning the first fuselage section relative tothe second fuselage section (operation 1700). This positioning isperformed with fuselage sections that have been changed in shape usingthe process illustrated in FIG. 13.

The process then joins the first fuselage section with the first desiredshape to the second fuselage section with the second desired shape(operation 1702) with the process terminating thereafter. In operation1702, the joining of the first fuselage section with the second fuselagesection may be made using different types of techniques. For example,the two fuselage sections may be joined using at least one of a buttjoint, a splice joint, or some other suitable mechanism.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of a module, a segment, a function,or a portion of an operation or step. For example, one or more of theblocks may be implemented as program code, in hardware, or a combinationof the program code and hardware. When implemented in hardware, thehardware may, for example, take the form of integrated circuits that aremanufactured or configured to perform one or more operations in theflowcharts or block diagrams. When implemented as a combination ofprogram code and hardware, the implementation may take the form offirmware.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, operation 1502 and operation 1504 may be performed inreverse order. In another example, operation 1502 and operation 1504 maybe performed at substantially the same time.

As another illustrative example, measurements may be made in a singlefuselage section rather than to fuselage sections in the processillustrated in FIG. 15. In yet other illustrative examples, the processmay be applied to measurements being made for three or more fuselagesections. In this type of implementation, additional laser trackers maybe placed between fuselage sections.

In still another illustrative example, operation 1502 in FIG. 15 may beomitted in some illustrative examples. The placing of the targets may beomitted, for example, when the targets are features on the fuselagesections.

The illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1800 as shown inFIG. 18 and aircraft 1900 as shown in FIG. 19. Turning first to FIG. 18,an illustration of an aircraft manufacturing and service method isdepicted in the form of a block diagram in accordance with anillustrative embodiment. During pre-production, aircraft manufacturingand service method 1800 may include specification and design 1802 ofaircraft 1900 in FIG. 19 and material procurement 1804.

During production, component and subassembly manufacturing 1806 andsystem integration 1808 of aircraft 1900 in FIG. 19 takes place.Thereafter, aircraft 1900 in FIG. 19 may go through certification anddelivery 1810 in order to be placed in service 1812. While in service1812 by a customer, aircraft 1900 in FIG. 19 is scheduled for routinemaintenance and service 1814, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 1800may be performed or carried out by a system integrator, a third party,an operator, or some combination thereof. In these examples, theoperator may be a customer. For the purposes of this description, asystem integrator may include, without limitation, any number ofaircraft manufacturers and major-system subcontractors; a third partymay include, without limitation, any number of vendors, subcontractors,and suppliers; and an operator may be an airline, a leasing company, amilitary entity, a service organization, and so on.

With reference now to FIG. 19, an illustration of an aircraft isdepicted in the form of a block diagram in which an illustrativeembodiment may be implemented. In this example, aircraft 1900 isproduced by aircraft manufacturing and service method 1800 in FIG. 18and may include airframe 1902 with plurality of systems 1904 andinterior 1906. Examples of systems 1904 include one or more ofpropulsion system 1908, electrical system 1910, hydraulic system 1912,and environmental system 1914. Any number of other systems may beincluded. Although an aerospace example is shown, different illustrativeembodiments may be applied to other industries, such as the automotiveindustry. Apparatuses and methods embodied herein may be employed duringat least one of the stages of aircraft manufacturing and service method1800 in FIG. 18.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 1806 in FIG. 18 may befabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 1900 is in service 1812 in FIG.18. As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 1806 and systemintegration 1808 in FIG. 18. For example, fuselage sections for aircraft1900 may be joined to each other to form the fuselage for an aircraft1900 during component and subassembly manufacturing 1806.

One or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized while aircraft 1900 is in service 1812, duringmaintenance and service 1814 in FIG. 18, or both. For example, duringrefurbishment of 1900 during maintenance and service 1814, one or moresections of the fuselage may be removed and replaced with new sectionsthat are joined using a fuselage manufacturing system. The use of anumber of the different illustrative embodiments may substantiallyexpedite the assembly of aircraft 1900, reduce the cost of aircraft1900, or both expedite the assembly of aircraft 1900 and reduce the costof aircraft 1900.

Thus, one or more of the illustrative embodiments provide a method andapparatus for processing fuselage sections to form the fuselage for anaircraft. In one illustrative example, an apparatus includes a cradlesystem, a metrology system, and a controller. The cradle system holdingthe fuselage section applies forces to the fuselage section to changethe current shape of the fuselage section. The metrology system makesmeasurements of the current shape of the fuselage section. Thecontroller receives measurements from the metrology system andidentifies the forces needed to change the current shape of the fuselagesection towards a desired shape for the fuselage section. This desiredshape is one that may be used to connect the fuselage section to anotherfuselage section.

With the apparatus in the different processes performed, joiningfuselage sections may be performed more easily and with less labor costas compared to currently used techniques. With an illustrative example,the fuselage section may be changed using a feedback loop to reach adesired shape for the fuselage section. Further, the number of humanoperators needed to perform the changes of measurements is fewer thanthose currently available systems for joining fuselage sections. In thismanner, an illustrative example may provide for a better fit betweenfuselage sections, the reduction in cost in joining fuselage sections,reduced amounts of labor needed to join fuselage sections, or somecombination thereof.

With respect to the metrology system, in one illustrative embodiment, amethod for measuring fuselage sections is provided. A scanning system ispositioned between a first fuselage section held in a first cradle and asecond fuselage section held in a second cradle. A group of beams oflight is transmitted from the scanning system to targets on a firstinterior surface of the first fuselage section and a second interiorsurface of the second fuselage section. A reflected light is detectedfrom a beam of light.

Measurements of the first fuselage section and the second fuselagesection are generated from using the reflected light generated inresponse to the beam of light. The measurements enable shaping at leastone of the first fuselage section and the second fuselage section forjoining the first fuselage section to the second fuselage section.

The process also places the targets on the first interior surface of thefirst fuselage section and the second interior surface of the secondfuselage section. Also, generating the measurements may compriseidentifying a current shape of the first fuselage section and the secondfuselage section. In an illustrative example, generating themeasurements also may comprise identifying a difference between thecurrent shape of the first fuselage section and a desired shape for thefirst fuselage section.

In another illustrative example, the current shape is a first currentshape and a desired shape is based on at least one of the first currentshape of the first fuselage section and a second current shape of thesecond fuselage section or parameters specified by a design for thefirst fuselage section. In an illustrative example, the current shapeand the desired shape are contours for the first fuselage section.

The process for measuring fuselage sections may include repeatingtransmitting the group of beams of light from the scanning system to thetargets on the first interior surface of the first fuselage section andthe second interior surface of the second fuselage section; detectingthe reflected light from the group of beams of light; and generating themeasurements of the first fuselage section and the second fuselagesection from using the reflected light generated in response to thegroup of beams of light, wherein the measurements enable shaping atleast one of the first fuselage section and the second fuselage sectionfor joining the first fuselage section to the second fuselage sectioneach time a current shape of the first fuselage section is changed. Inone illustrative example, the scanning system is an optical metrologysystem and includes at least one of a lidar system or a laser scanningsystem.

The process also may send the measurements from the scanning system to acontroller that identifies forces needed to change a current shape ofthe first fuselage section to a desired shape for connecting the firstfuselage section to the second fuselage section and sends commands to acradle system to apply the forces to change the current shape of thefirst fuselage section towards the desired shape. In an illustrativeexample, the measurements are generated without the scanning systemcontacting the first fuselage section and the second fuselage section.In an illustrative example, the scanning system and the targets form ametrology system.

In another illustrative embodiment, another method for measuringfuselage sections is provided. A scanning system is positioned between afirst fuselage section held in a first cradle and a second fuselagesection held in a second cradle. Measurements of the first fuselagesection and the second fuselage section are generated using the scanningsystem. The measurements enable shaping at least one of the firstfuselage section and the second fuselage section for joining the firstfuselage section to the second fuselage section. In an illustrativeexample, the process also may place targets on a first interior surfaceof the first fuselage section and a second interior surface of thesecond fuselage section. In another illustrative example, the processalso may send the measurements from the scanning system to a controllerthat identifies forces needed to change a current shape of the firstfuselage section to a desired shape for connecting the first fuselagesection to the second fuselage section and sends commands to a cradlesystem to apply the forces to change the current shape of the firstfuselage section towards the desired shape

In generating measurements, the process may transmit a beam of lightfrom the scanning system to targets on a first interior surface of thefirst fuselage section and a second interior surface of the secondfuselage section; detect reflected light from the beam of light; andgenerate the measurements of the first fuselage section and the secondfuselage section from using the reflected light generated in response tothe beam of light. In an illustrative example, the scanning system is anoptical metrology system and includes at least one of a lidar system ora laser scanning system.

In yet another illustrative embodiment, a metrology system for measuringfuselage sections is provided. The metrology system comprises a scannerthat transmits a group of beams of light from the scanning system totargets on a first interior surface of a first fuselage section and asecond interior surface of a second fuselage section. The scannerfurther detects a reflected light from the beam of light and generatesmeasurements of the first fuselage section and the second fuselagesection from using the reflected light generated in response to the beamof light. The measurements enable shaping at least one of the firstfuselage section and the second fuselage section for joining the firstfuselage section to the second fuselage section.

In an illustrative example, the scanner sends the measurements to acontroller that identifies forces needed to change a current shape ofthe first fuselage section to a desired shape for connecting the firstfuselage section to the second fuselage section and sends commands to acradle system to apply the forces to change the current shape of thefirst fuselage section towards the desired shape. In anotherillustrative example, the group of beams of light is a group of laserbeams. In an illustrative example, the metrology system may furtherinclude the targets, wherein the targets are selected from at least oneof a reflective tape, a tooling ball, or a feature on one of the firstfuselage section and the second fuselage section.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherdesirable embodiments. The embodiment or embodiments selected are chosenand described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. An apparatus comprising: a holding structure thatholds a fuselage section; an actuator system that applies forces to acircumference of the fuselage section while the fuselage section is heldin the holding structure in which the forces change a current shape ofthe circumference of the fuselage section towards a desired shape whencommands are received from a controller; a feedback loop comprising theholding structure, a self-referential metrology system that scanstargets on the fuselage section and measures the current shape of thefuselage section, and a controller that identifies the forces, whereinthe feedback loop is responsive to changes in the current shape thathave not reached the desired shape and provides incremental changes inthe current shape in order to reach the desired shape; and a modelingsystem that determines values for the forces to be applied to thecircumference of the fuselage section according to a model of howdifferent forces effect a current shape of the fuselage.
 2. Theapparatus of claim 1, wherein the holding structure is a first holdingstructure, the actuator system is a first actuator system, the fuselagesection is a first fuselage section, the current shape is a firstcurrent shape, and the desired shape is a first desired shape andfurther comprising: a second holding structure that holds a secondfuselage section; and a second actuator system that applies secondforces to the second fuselage section while the second fuselage sectionis held in the second holding structure in which the second forceschange a second current shape of the second fuselage section towards asecond desired shape when the commands are received from the controller.3. The apparatus of claim 2, wherein the first desired shape and thesecond desired shape are selected for joining a first end of the firstfuselage section to a second end of the second fuselage section.
 4. Theapparatus of claim 1, wherein the actuator system applies the forces toa portion of the fuselage section to cause the change in the currentshape of the fuselage section.
 5. The apparatus of claim 4, wherein theactuator system applies the forces to a portion of a first fuselagesection at an end of the fuselage section.
 6. The apparatus of claim 4,wherein the portion is about one half of a circumference of the fuselagesection.
 7. The apparatus of claim 1, wherein the actuator systemcomprises: actuators.
 8. The apparatus of claim 7, wherein the actuatorsystem further comprises: a frame, wherein the actuators are physicallyassociated with the frame and the frame holds the actuators in positionsaround the fuselage section when the fuselage section is held in acradle.
 9. The apparatus of claim 7, wherein the actuators arepositioned at an end of the fuselage section held in the holdingstructure.
 10. The apparatus of claim 7, wherein the actuators areselected from at least one of a linear actuator, a hydraulic actuator, apneumatic actuator, or an electro mechanical actuator.
 11. A method forshaping fuselage sections, the method comprising: holding a firstfuselage section in a holding structure in a cradle in a cradle system;applying forces to a circumference of the first fuselage section with anactuator system to a portion of the first fuselage section such that afirst current shape of the first fuselage section changes towards afirst desired shape for the first fuselage section to join the firstfuselage section to a second fuselage section; and responsive to changesin the first current shape that have not reached the first desiredshape, employing a feedback loop to provide incremental changes in thefirst current shape in order to reach the first desired shape, whereinthe feedback loop comprises the holding structure, a self-referentialmetrology system that scans targets on the first fuselage section andmeasures the first current shape of the first fuselage section, and acontroller that identifies the forces, wherein the controller identifiesthe forces to be applied to the circumference of the fuselage sectionaccording to a model of how different forces effect a current shape ofthe fuselage.
 12. The method of claim 11, wherein the cradle is a firstcradle, the holding structure is a first holding structure, and whereinthe holding step comprises: holding the second fuselage section in asecond cradle in the cradle system.
 13. The method of claim 12 furthercomprising: positioning the first fuselage section held in the firstcradle relative to the second fuselage section held in the secondcradle; and joining the first fuselage section with the first desiredshape to the second fuselage section with a second desired shape afterpositioning the first fuselage section held in the first cradle relativeto the second fuselage section held in the second cradle.
 14. The methodof claim 11, wherein the holding structure is a first holding structure,the cradle is a first cradle, the actuator system is a first actuatorsystem, the portion is a first portion, the desired shape is a firstdesired shape, and further comprising: holding the second fuselagesection in a second holding structure in a second cradle in the cradlesystem; and applying second forces to the second fuselage section with asecond actuator system to a second portion of the second fuselagesection such that a second current shape of the second fuselage sectionchanges towards a second desired shape for the second fuselage sectionto join the first fuselage section to the second fuselage section havingthe second current shape that is substantially the same as the firstcurrent shape.
 15. The method of claim 11, wherein the second fuselagesection has a second desired shape, the first desired shape and thesecond desired shape are selected for joining a first end of the firstfuselage section to a second end of the second fuselage section.
 16. Themethod of claim 11, wherein the actuator system applies the forces tothe portion of the first fuselage section at an end of the firstfuselage section.
 17. The method of claim 11, wherein the portion isabout one half of a circumference of the first fuselage section.
 18. Themethod of claim 11, wherein the actuator system comprises: actuators;and a frame, wherein the actuators are physically associated with theframe and the frame holds a plurality of actuators in portions aroundthe first fuselage section when the first fuselage section is held inthe cradle.
 19. The method of claim 18, wherein the actuators areselected from at least one of a linear actuator, a hydraulic actuator, apneumatic actuator, or an electro mechanical actuator.